Nested Container Filling with In-Process Weighing
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Solution Overview
Problem
Current filling systems for pharmaceutical and cosmetic containers face challenges in accurately monitoring the fill level during the filling process, leading to potential underfilling or overfilling, which can result in health risks or reduced product effectiveness, and require interruptions for weighing, limiting processing speed and accuracy.
Innovation Solution
A device with a conveyor system, gripping devices, and a weighing station that allows for simultaneous removal, filling, and reweighing of containers without interrupting the filling process, enabling in-process control and ensuring all containers are checked for accurate fill levels, with a control unit managing the gripping devices and weighing stations to maintain continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If containers are removed from the nest for weighing before and after filling, then the fill level can be accurately determined, but the filling process is interrupted and processing speed is reduced
Solution Approach 1:
The weighing station performs preliminary weighing of empty containers before they reach the filling station. This allows the system to prepare weighing data in advance, so that after filling, only the net content weighing is needed, significantly reducing the time required post-filling and minimizing process interruptions
Solution Approach 2:
The conveyor system is designed to continuously transport nests through the filling station while the weighing station operates in parallel. The gripping device transfers individual rows to the weighing station without stopping the main conveyor, allowing weighing operations to continue alongside filling operations, thereby maintaining continuous productive action
2Measurement precision
If the filling process is interrupted to weigh containers, then accurate net content determination is possible, but time is lost and production efficiency decreases
Solution Approach 1:
Empty container weighing is performed in advance before filling occurs. This preliminary measurement allows the system to have baseline data ready, so that after filling, only a quick re-weighing is needed to determine net content, dramatically reducing the time loss compared to weighing complete containers from scratch after filling
Solution Approach 2:
Instead of weighing all containers individually after filling, the system weighs a representative sample or uses statistical methods based on partial weighing data. This partial action approach provides sufficient accuracy for quality control while minimizing the time required for the weighing process
3Reliability
If containers are weighed individually after filling, then each container's fill level can be verified, but the complexity of the system increases
Solution Approach 1:
The weighing station is integrated into the existing conveyor system and nesting structure. The same conveyor that transports nests to the filling station also brings them to the weighing station, and the gripping device used for filling also performs the transfer to weighing. This merging of functions reduces overall system complexity despite the added verification capability
Solution Approach 2:
The weighing station is designed to handle multiple functions: weighing empty containers before filling, weighing filled containers after filling, and potentially weighing nests containing multiple containers. This multi-functionality reduces the need for separate dedicated systems for each weighing task, thereby controlling system complexity while enhancing verification reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for real-time monitoring and adjustment of the filling process, ensuring all containers are accurately filled without interruptions, maintaining normal processing speed and achieving high accuracy in fill levels, thus preventing errors and ensuring product quality.
Implementation Method 1
a weighing station (28) for weighing a row of containers (14)
Data Source
Figure 1~2a
Figure 2b~3b
Figure 4
AI summary
The present invention relates to a filling device (10) for filling nested containers (14) which are arranged in at least one row in a nest (12) and can be conveyed by means of a conveying device (16), comprising a filling station (26) for simultaneously filling the containers (14) of a row, comprising at least one weighing station (28) for weighing a row of the containers (14), comprising a first gripping device (18) for simultaneously removing a row of containers (14) to be filled and transferring these containers (14) to a first weighing station (28a) of the at least one weighing station (28) and transferring the weighed containers (14) from the at least one weighing station (28) back to the nest (12) or another nest (12').The filling device (10) also has a second gripping device (20) for the simultaneous removal of a series of filled and weighed containers (14) and for transferring these containers (14) to the first weighing station (28a) or to a second weighing station (28b) of the at least one weighing station (28) and for transferring the series of filled and twice weighed containers (14) from the at least one weighing station (28) back into the nest (12) or another nest (12', 12").